Journal of Ambient Intelligence and Humanized Computing (2019) 10:1129–1140

https://doi.org/10.1007/s12652-018-0946-5

ORIGINAL RESEARCH

Digital twin for CNC machine tool: modeling and using strategy

Weichao Luo1,2,3 · Tianliang Hu1,2,3   · Chengrui Zhang1,2,3 · Yongli Wei1,2,3

Received: 31 March 2018 / Accepted: 19 July 2018 / Published online: 28 July 2018
© Springer-Verlag GmbH Germany, part of Springer Nature 2018

Abstract
As a typical manufacturing equipment, CNC machine tool (CNCMT), which is the mother machine of industry, plays an
important role in the new trend of smart manufacturing. As the requirement of smart manufacturing, the abilities of its self-
sensing, self-prediction and self-maintenance are necessary. In order to make CNCMT become more intelligent, a research
about Digital twin (DT) for CNCMT is conducted. In this research, a multi-domain unified modeling method of DT is
established, a mapping strategy between physical space and digital space is explored, and an autonomous strategy of DT is
proposed. These methods can optimize the running mode, reduce the sudden failure probability and improve the stability
of CNCMT. Finally, this paper provides a demonstration of DT model building and using strategy in fault prediction and
diagnosis for CNC milling machine tool.

Keywords  CNC machine tool (CNCMT) · Digital twin (DT) · Smart manufacturing

1 Introduction reconfigurable and self-organizing capabilities, as well as

Nowadays, the concept of CPS (Cyber-physical systems)
(Lee 2008; Lee et al. 2015) is widely used in industry. With
the application of the key technology of real-time sensing,
advanced control theory, artificial intelligence (AI) and
service oriented manufacturing, under the concept of CPS,
smart manufacturing becomes a new trend, which makes
complex and customized manufacturing and cooperation
become possible. Smart manufacturing (Tao et al. 2017a, b;
Davis et al. 2012) is an interdisciplinary technology integrat-
ing sensing and analysis of production information, repre-
sentation of experience and knowledge as well as intelligent
decision-making based on these information, data, experi-
ence and knowledge. It has five features: autonomous abil-
ity, human–computer interaction, modeling and simulation,
* Tianliang Hu
tlhu@sdu.edu.cn
1
School of Mechanical Engineering, Shandong University,
Jinan 250061, People’s Republic of China
2
Key Laboratory of High Efficiency and Clean Mechanical
Manufacture, Shandong University, Ministry of Education,
Jinan, China
3
National Demonstration Center for Experimental Mechanical
Engineering Education, Shandong University, Jinan, China
learning and self-maintenance ability.
In recent years, with the requirement of smart manufac-
turing mode, developed from CPS concept, the appearance
of digital twin (DT) (Grieves and Vickers 2017; Glaessgen
and Stargel 2012) technology provides an effective reso-
lution to integrate the physical world and the information
world. DT is a complete virtual prototype of an entire sys-
tem, which can real-time reflect the all life cycle of physical
device or product. With DT, requirements of multiple engi-
neering disciplines are integrated and system level simula-
tion and self-decision can be done based on its real-time
mapping data in the entire lifecycle.
CNC machine tool (CNCMT), which is the mother
machine of industry (Xu and Newman 2006), is an important
equipment in smart manufacturing. In smart manufacturing
mode, it must have the following abilities in order to ful-
fill complex machining task and customized manufacturing
requirement.
1.1 Precise simulation
The design parameter and actual working conditions are
different in CNCMT. Simulation of CNCMT model should
consider the data and information gathered from physical
equipment. Precise simulation will integrate multi-domain

13
Vol.:(0123456789)

1130
modeling and simulation with accurate and reliable data
from CNCMT.
1.2 Self‑sensing
Self-sensing is the first step in developing a CPS for
CNCMT. Self-sensing can acquire accurate and reliable
data from CNCMT and its components, and then inference
meaningful information from the data.
1.3 Self‑adjustment
CNCMT with self-adjustment ability can adjust itself for
less time, less waste and better quality according to produc-
tion task. It can also adjust itself to make the production
generate minimum user concerns.
1.4 Self‑prediction
CNCMT may incur different faults irregularly, which will
cause bad precision and affect the production. CNCMT
with self-prediction ability can monitor and predict the
fault timely according to environment and its own condi-
tions before serious faults occur.
1.5 Self‑assessment
CNCMT with self- assessment ability can evaluate the run-
ning status, optimize working parameters, and make deci-
sions based on machine learning.
In order to make CNCMT intelligent enough to achieve
the above abilities, a research on DT of CNCMT (DTMT) is
conducted in this paper. DTMT is a real-time digital replica
of CNCMT. DT is enabled by highly developed computing,
high precision simulation, and rapid developing artificial
intelligence technology. Driven by ultrahigh fidelity model
and machine learning based on accurate data, expertise and
domain knowledge can be expressed by algorithm model.
Therefore, DTMT has ability to do precise simulation, self-
sensing, self-adjustment, self-prediction and self-assessment
like expert. It can be used in design, manufacturing, usage,
maintenance and recycling stage of CNCMT. With DTMT,
a unified model is used in the entire lifecycle of CNCMT,
and is tightly driven by unified and real-time sensed data, on
purpose to fulfill complex machining task, reduce downtime
of unplanned maintenance, increase machining efficiency,
and make maximum reuse of parts during recycling.
To build a DTMT, unified model, real-time sensed data
support and intelligent using strategy are very important.
In this research, a multi-domain unified modeling method
of DT is established, a mapping strategy between physical
space and digital space is designed. Based on them, a using
strategy of DT is explored.
13
W. Luo et al.
The rest of this paper is organized as follows. In Sect. 2,
relevant modeling researches and DT concept are intro-
duced. Section 3 presents an application scenario of DT for
CNCMT. Section 4 discusses the description, mapping and
autonomous methods of DTMT. Section 5 puts forward a
case study: fault prediction and diagnosis of CNCMT using
DTMT. Section 6 concludes this study and points out the
future works.
2 Related works
2.1 DT concept
With the development of IoT (Ji et al. 2015; Tao et al. 2017a,
b), big data, and machine learning (Wang et al. 2018), many
companies and scholars have put forward DT concept and
explored the application of DT. NASA studied the health
maintenance and guarantee of aerospace aircraft with the
guidance of DT (Tuegel et al. 2011; Kraft 2015). Lee J pro-
posed a unified 5-level architecture as a guideline for imple-
mentation of CPS (Lee et al. 2015). Schroeder et al. (2016)
proposed the use of AutomationML to model attributes
related to DT and proposed that this model was very useful
for data exchange between different systems connected with
DT. Aitor Moreno presented the process to construct a DT
for a sheet metal punching machine to support the interac-
tive design of optimal NC machining programs (Moreno
et al. 2017). TaoFei put forward the concept of Digital Twin
Workshop and Digital Twin driven prognostics and health
management for complex equipment (Tao et al. 2018; Fei
et al. 2017). Many leading companies such as PTC, ANSYS
(Magargle et al. 2017), GE, and Siemens also explored more
applications under the guidance of DT concept.
DT is a new idea about CPS model of physical assets,
which is a kind of dynamic digital representation that ena-
bles companies to understand, predict, and optimize the per-
formance of their machines and their business. The main
features of it are as below:
1. DT is a multi-domain and ultrahigh fidelity digital model
integrating different subjects such as mechanical, electri-
cal, hydraulic, and control subjects. It connects multiple
product activities, and is a consistent model supporting
design, production, operation, maintenance, and recy-
cling lifecycle stage.
2. DT acts as a virtual mapping of physical products—a
digital shadow containing all the information and knowl-
edge. It connects with physical entity, and gets data from
the physical world. It can keep consistent with the physi-
cal world through dynamic update.
3. DT can perceive its status according to its synchronous
update with physical entities, and can predict what will
Digital twin for CNC machine tool: modeling and using strategy 1131
happen then make decisions according to the analysis of
historical and current data. It has intelligent interaction
with physical entities, such as self-sensing, self-predic-
tion and self-maintenance based on machine learning.
However, there is no an application scenario of DT for
CNCMT currently. Through building DT and applying it
on CNCMT, intelligent data analysis and applications can
be realized, and then smart manufacturing will has an effi-
cient foundation. Nevertheless, the model of CNCMT is
about multi-domain and different subjects, and an effective
modeling, mapping and autonomous method has not been
proposed yet. To fill the vacancy, an application scenario of
DT for CNCMT is analyzed and presented in this research.
2.2 Modeling and simulation method of CNCMT
In traditional virtual prototype modelling process of
CNCMT, which is shown in Fig.  1, developers usually
design digital model based on design parameters using CAD
software. After the virtual prototype is verified, components
will be produced and assembled, a physical prototype will
be done and then improvement will be made according to
the verification result of the physical prototype. After all
design goals have been reached, CNCMT is then delivered to
users. However, the consistency between designed working
conditions and actual working conditions cannot be ensured.
This method relies on statistics of material properties, heu-
ristic design ideas, physical tests and assumed similarities
between the tests and operating conditions. Design and cost
Design parameters Design
Virtual prototype verification
Components produce & assemble
Prototype
Improvement
(by hand and not real time) No
Specify
Yes
Using
Maintenance
Fault
No
Yes
Stop and Task delay Repair
Yes
Suceed
No
Recycle
Fig. 1  Traditional building process of CNCMT
control cannot strike a balance between benefit and quality
simultaneously.
However, subsystems, like mechanical subsystem, electri-
cal subsystem and hydraulic subsystem of CNCMT, are usu-
ally designed, analyzed, debugged and experimented inde-
pendently by different developers using different software.
The independent design pattern overemphasizes details
rather than the overall performance and coupling between
each component, which will cause numerous design itera-
tions. In addition, most of the simulations are performed in
design stage, which cannot reflect the real running condition.
CNCMT is a complex mechatronic system contain-
ing many objects with lots of properties. In order to fulfill
the requirement of DTMT, all lifetime stages of CNCMT
need to be integrated tightly with a multi-domain unified
model. With this model, overall performance and coupling
between each component will be considered, and this is an
essential basis to realize self-adjustment, self-prediction and
self-assessment of DTMT. At present, multi-domain system
modeling and simulating methods contain software interface
method, high level architecture (HLA) and unified modeling
language (UML).
1. Software interface is a modeling method based on corre-
sponding interface of commercial software for interdis-
ciplinary fields, such as ANSYS, ADAMS, MATLAB/
Simulink, SABER, and so on (Wang 2002). All kinds
of above software are quite mature due to the accumu-
lation of relevant professional knowledge, but the inter-
face compatibility between different software platform
increased the difficulties of development.
2. HLA (Pedrielli et al. 2011) is an advanced simulation
structure with many advantages in the aspects of stand-
ardization, openness, and scalability, with support for
distributed simulation. It supports simulation for con-
tinuous system or discrete time system. However, HLA
Improvement
needs various interface of commercial simulation soft-
ware developed with HLA, which is similar to the soft-
ware interface method.
3. UML method mainly focuses on the multi-domain uni-
fied modeling language Modelica (M Association 2005;
Elmqvist et al. 1998). Modelica is an equation modeling
language which was put forward in 1997, based on a
variety of modeling language. It solved the problems
of unified modeling and collaborative simulation in
multi-physical systems. Modelica language has many
advantages in model reusability and convenience. The
modeling ideas of Modelica meet the accumulation,
reusability, and reconstitution of knowledge.
All these methods provide an effective modelling and
simulation solution for building DTMT, but there is lack of
accurate and reliable data in these methods.
13

1132
2.3 Data using strategy
Traditionally, running or faults data always rely on user’s
feedback or manual records, which will inevitably result
in the loss of accuracy and instantaneity. In this way,
comprehensive, objective and real-time design improve-
ment according to the CNCMT running status cannot be
realized.
Precise simulation, self-sensing, self-adjustment, self-
prediction and self-assessment are the main using focus
based on DTMT. To fulfill these requirements, sensed
data need to be used and analyzed. Some scholars have
used cluster analysis, BP neural network or SVM algo-
rithm to predict and diagnose the fault of important parts
such as bearing, spindle, and servomotor based on data-
driven method. For example, Cho et al. (2005) proposed
an intelligent tool breakage detection system which used
a support vector machine (SVM) learning algorithm, JS
Zhang realized the CNC fault diagnoses based on RBF
neural network algorithm (Zhang and Zhang 2012). Wang
J presents a new deep neural network model for optimized
condition prognosis (Wang et al. 2018) and a new virtual
tool wear sensing technique for tool condition monitoring
(Wang et al. 2016). Fuzzy neural network is a combina-
tion of artificial neural network and adaptive fuzzy logical
system, and has many advantages in knowledge presenta-
tion, storage and inference. YK Liu, H Xia applied fuzzy
neural network to the nuclear power plant, and built fault
diagnostic system (Liu et al. 2004). Long and Wang (2009)
applied expert system and fuzzy artificial neural network
(ANN) to solve the problem of fault diagnosis in the air-
craft fuel system.
All above researches provide effective strategies of
data using methods. Nevertheless, these methods do not
Fig. 2  System composition of
CNCMT
13
W. Luo et al.
consider the digital model of physical product. If multi-
domain modelling, simulation and reliable data using strat-
egy are combined in DTMT, CNCMT will become more
intelligent.
3 Application scenario of DT for CNCMT
3.1 Characteristics of CNCMT
Computer numerical control (CNC) technology is a kind of
technology using digital information to control and machin-
ing process. CNCMT is kind of machine tool equipped with
CNC system. CNCMT is widely used in processing com-
plex, precise, multi-varieties and small batch parts. As a
typical mechatronic equipment, it is a kind of flexible, highly
efficient automatic machine tool.
The basic components of CNCMT are control system,
servo system, functional unit and auxiliaries, which are
shown in Fig. 2. The control system is the brain of CNCMT,
which consists of CNC, PLC, HMI and I/O. The servo sys-
tem receives the signal from control system, and then con-
verts it to linear motion or angular motion after signal ampli-
fier and processing. The functional unit is the components
carrier of CNCMT and most of them are mechanical parts. It
contains worktable, guide rail, lead screw, spindle unit, tool
magazine and so on. The auxiliary equipment includes chip
conveyor, hydraulic system, pneumatic system, lubrication
system, coolant system and protection devices.
Data gathered from CNCMT is complex and coupled.
Therefore, different subjects and data are also coupled
when building a digital model. In data driven application of
DTMT, data should be decoupled and then analyzed when
using the digital model. Based on multi-domain digital
Digital twin for CNC machine tool: modeling and using strategy 1133
modelling and intelligent application of DT, with the data
driven application, precise simulation, self-sensing, self-
adjustment, self-prediction and self-assessment can be con-
ducted. The DT modeling and application framework for
CNCMT is presented below.
3.2 DTMT modeling and application framework
Considering data driven using purpose, DTMT should have
abilities of coupling and decoupling multi-source data,
data mapping and data storage. To achieve these abilities, a
framework is designed as shown in Fig. 3.
1. In order to make DTMT have ability to sense CNCMT
and its environment, a sensing system is needed. With
this sensing system, data and information from physical
space are mapped to DTMT for analysis and decision-
making. The physical space contains a physical CNCMT
and different types of sensors to monitor temperature,
pressure, velocity, position, vibrating and so on.
2. In the digital space, DTMT consists of DTMT descrip-
tive model and DTMT algorithm model. The main func-
tion of descriptive model is to describe the geometric,
physical, and electrical characteristic of CNCMT. The
DTMT descriptive model relates to multiple subjects
and fields, so the key is to composite interdiscipli-
nary knowledge accurately to build DTMT descriptive
Fig. 3  DTMT modeling and application framework
model. The DTMT algorithm model stores and analyzes
the running status data, then makes decisions using
machine-learning algorithm.
3. DTMT is a real-time one-to-one mapping of CNCMT,
so effective mapping strategy has big difference with
traditional equipment. To allow access to standardized
reading and writing of current data in CNC system and
sensors, a DTMT mapping model needs to be built. The
DTMT mapping model, which is designed as an inter-
face of communication drivers, makes the DTMT react
with physical CNCMT in real-time. As shown in Fig. 3,
the DTMT mapping model consists of a mapping model
server, a mapping model client, and a data-mapping dic-
tionary. The mapping model services are the interface
between servers as supplier of an information model and
clients as consumers of that information model.
Building and applying DT for CNCMT is a way to
quickly predict, determine and optimize product properties.
After the CNCMT deployment, DTMT can react with the
physical machine tool timely, conducting intelligent applica-
tions and fault forecast based on data collected and analyzed
from CNCMT.
4 Implementation of DTMT
According to the DTMT framework proposed in Sect. 3, a
design method of DTMT which contains DTMT descriptive
model, DTMT mapping model and DTMT algorithm model
is proposed.
4.1 Design of DTMT descriptive model
DTMT descriptive model is important because it is the digi-
tal presentation of physical CNCMT and the basis of DTMT
algorithm model. To describe the essence of real world, the
DTMT descriptive model should contain mechanical subsys-
tem, electrical subsystem, hydraulic subsystem and so on.
CNCMT is a multi-domain and complex mechanical sys-
tem. To build the DTMT descriptive model and make it easy
to use, a hierarchical and encapsulated method should be
used. Moreover, the description of DTMT complex relation-
ship needs an effective modeling language. Object-oriented
modelling method is used because of its good encapsulation
ability of CNCMT object. The modelling language used is
modelica, a multi-domain unified modeling language with
object-oriented feature.
With above method and modelling language, CNCMT is
divided into multiple subsystems such as mechanical, elec-
trical, hydraulic subsystem, then attributes and functions of
different objects are determined. Take mechanical subsystem
of DTMT for example, it contains main body, feed system,
13

1134 W. Luo et al.

and spindle system; while the feed system contains drivers,
motors, ball screw, and guide rail; finally the motors and its
components; at the same time, different objects have their
own functions.
Then subsystem engineers determined the mathemat-
ics equations of CNCMT by modelica, according to exist-
ing experiences and parameters. For example, as shown in
Fig. 4, different engineers build relevant subsystem based on
constraints and calculation equations. Finally, different parts
are connected through interface between them and different
subsystems are connected through energy convertor. Using
above method, a parameterized, modular and mathematical
DTMT descriptive model can be built in the modeling and
simulation environment.
OLE for Process Control Unified Architecture (OPC UA)
is widely used today as standardized interface between auto-
mation systems. It enables a platform-independent interoper-
ability standard for moving data between factory floor and
the enterprise. Mapping method is designed according to the
OPC UA standards in this research.
As shown in Fig. 5, running data are gathered from vari-
ous sensors and CNC controller then uploaded to DTMT
mapping model server. The mapping model server contains
four layers. Physical interface layer implements the compat-
ibility of different interfaces such as RS485, RS232, Wi-Fi,
Bluetooth, CAN and so on. Protocol driver layer provides
a common read and write method for different interfaces.

4.2 Design of DTMT mapping strategy

DTMT acts as a mapping shadow of physical CNCMT and

reacts with it in real-time. Therefore, an efficient real-time
mapping strategy between DTMT and CNCMT is necessary.
What is more, working conditions of CNCMT comprise kin-
ematics, dynamics, and thermodynamics parameters accord-
ing to different subjects. Data acquired from CNCMT is cou-
pled, multi-sources and heteroid. To realize the data-driven
applications of DTMT, a mapping model supporting from
simple to complex data with expandability is needed. At the
same time, platform-independent interfaces and interoper-
ability of mapping model are still important. What`s more,
running data of CNCMT is enormous, complex, unstruc-
tured and update rapidly, so column database is suitable for
the storage of data. Fig. 5  DTMT mapping strategy

Fig. 4  Multi-physical modeling
of CNCMT based on UML
Modelica

13
Digital twin for CNC machine tool: modeling and using strategy 1135
Data parsing layer realizes data processing from different
communication protocol. Finally information model layer
convert various data to information based on data-mapping
dictionary. The data-mapping dictionary provides detailed
information about the CNCMT data, such as standard defini-
tions of data elements, their meanings, and allowable values.
After parsing and transformation of the protocol by
mapping model server, running data is uploaded to DTMT
descriptive model and DTMT database. The solver and
post-processor in DTMT descriptive model can conduct the
working condition loading and system simulation of DTMT.
Through mining the running data by machine learning algo-
rithms, wrong working condition and design defects can be
found.
4.3 Design of DTMT algorithm model
Intelligent CNCMT, as a key intelligent manufacturing
equipment, should has precise simulation, self-sensing,
self-adjustment, self-prediction and self-assessment abili-
ties. All above abilities need support of DTMT algorithm
model. Based on DTMT descriptive model and information
from mapping model, DTMT algorithm model can provides
some intelligent services driven by running data.
DTMT algorithm model is shown in Fig.  6, and it
mainly consists of database, knowledge base, inference
Fig. 6  DTMT algorithm model
engine, control mechanism and intelligent services driven
by machine learning. Mapping model client transfers man-
ufacturing information and fault data from physical space
to DTMT algorithm model. Database stores the real-time
and historical data gathering from CNCMT. Knowledge
base contains a set of knowledge learned trough relevant
artificial neural networks algorithm. Rules for knowledge
base refine from history maintenance data and are pro-
vided for inference engine. Expertise and domain knowl-
edge are expressed by rules in knowledge base. Through
analysis and decision-making driven by machine learning
algorithm, DTMT algorithm model will provide several
intelligent services such as design improvement, running
optimization, fault prediction and accurate maintenance.
Therefore, DTMT will achieve goals like precise simu-
lation, self-sensing, self-adjustment, self-prediction and
self-assessment.
Take fault diagnosis as an example, the algorithm model
is trained with fault phenomena as input and fault reason
as output. The knowledge and rules learnt by algorithm
model is stored in knowledge base. When CNCMT meets
a new fault, running and fault data are mapping to DTMT
algorithm model. Through analysis and inference by algo-
rithm model with relevant machine learning method, fault
reason and some decisions will be provided.
13

1136 W. Luo et al.

5 Case study CNC control system controls the servomotor and I/O using
EtherCAT industrial ethernet.
5.1 Problem description DTMT is built for this CNC milling machine to predict
left lifetime of ball screw and provide maintenance strategy.
CNC milling machine tool is an important kind of CNCMT The parameters of the experiment platform are shown in
and has a wide application. It consists of three servomotors Table 1.
(X, Y, and Z), a spindle, feed system, machine bed, and CNC
system. Since the component failures seriously affect the 5.2 DTMT implementation of CNC milling machine
production task, DT is necessary to predict and diagnose
the faults. CNC milling machine is a set of complex mechatronic
Ball screw is an important component of CNC milling equipment, which contains different subsystems and many
machine, which transforms the force from motor and guar- mechanical parts. To describe the essence of it, a DTMT is
antees machining accuracy. When CNC milling machine is built using modelica in MWorks software.
cutting materials, the main forces of ball screw are axial cut-
ting force, friction, and acceleration or deceleration impact.
Working conditions of ball screw are diverse, so regular Table 1  Parameters of CNC Parameters Values Units
milling machine
maintenance usually cannot fully guarantee reliable running.
X travel 500 mm
The lead screw and bearing of feed system are normally
Y travel 500 mm
encountered failure.
Z travel 300 mm
To validate the proposed method in this paper, a case
Ball screw lead 600 mm
study based on DTMT concept is presented. The experiment
Resolution 0.5 um
platform is shown in Fig. 7, according to the system require-
Repeat accuracy 5 um
ments. A three-axis CNC milling machine with position sen-
Rated load 15 kg
sors, vibrating sensors and velocity sensors are used. The
Speed ≤ 50 mm/s

Fig. 7  Experiment platform

13
Digital twin for CNC machine tool: modeling and using strategy 1137
5.2.1 DTMT descriptive model
It is an enormous task to model every part in detail. To
simplify the work, the model is simplified according to the
requirements, and it consists of the primary components
such as the guide, screw, slide, screw nut and machine bed.
After analyzing the mathematical model of feed system,
a DTMT descriptive model is built in MWorks. Since the
Fig. 8  DTMT mechanical descriptive model of X feed system
Fig. 9  Multi-domain model of X feed system
mechanical model of the whole machine tool is too large,
this paper only showed the X feed system in Fig. 8.
As shown in Fig. 9c, the DTMT descriptive model of
X feed system consists of a control box, a PMSM motor, a
mechanical descriptive model and some sensors. The control
box mainly contains a dq vector controller shown in Fig. 9a.
The dq vector controller consists of PI controllers and coor-
dinate transformation modules modeled by modelica. A
13

1138
permanent magnet synchronous motor (PMSM) is also mod-
eled by modelica. Input of the control model are target speed
value given by the host computer while output are pulse
width modulation signal produced by SVPWM module to
control the inverter effectively. The speed–current double
Fig. 10  Mapping model based on UML
Fig. 11  Data-mapping diction-
ary realized by XML
13
W. Luo et al.
semi-closed loop control system is realized by considering
the angular velocity and displacement of the motor detected
by sensors.
5.2.2 DTMT mapping model
The mapping model is developed based on UML. As shown
in Fig. 10, it has different nodes and different references
between nodes. The mapping model provides a structural
information model of CNC milling machine. The CNCMT
object type includes “CNC system” subtype, “Servo system”
subtype, “Functional unit” subtype and “Sensors” subtype;
meanwhile the “Feed motor” node has a X axis node, a Y
axis node and a Z axis node; the “Lead screw” node has
a screw node, a nut node and a slide node. Each node has
different events and values. The designed data-mapping
dictionary is expressed by XML as shown in Fig. 11. The
data-mapping dictionary corresponds to the mapping model
and will instantiate the mapping model when the DTMT is
running.
5.2.3 DTMT algorithm model
The fault of ball screw has a big uncertainty and residual life-
time prediction is basis for accurate fault predict model. Data
gathered from ball screw is multidimensional and time series.
Neural networks have good learning ability to approximate
any nonlinear function. The measurement value is small and
Digital twin for CNC machine tool: modeling and using strategy 1139

Fig. 12  Using method of DTMT

the accurate model cannot be obtained, the fuzzy logic sys-
tem can simulate the thinking of human brain and make a bet-
ter explanation. What is more, it can almost realize real-time
prediction. Therefore, in this paper, B-splines fuzzy neural
network is used for the fault predict model. Vibration sensors
are installed on the two sides of ball screw and temperature
sensors are installed on the supporting base. They are used to
monitor components of ball screw in real-time. The residual
lifetime of ball screw can be obtained after analyzing the
temperature and vibration values.
The basic function of B-splines can be expressed by:
hidden layer adopts the B-spline basis function defined on
the point matrix. Connection weight from the hidden layer
to the output layer changes with the learning sample dur-
ing training. The error of training model can be described
by known fault and model output. Known fault is used as
expected result and compared with training result to training
the algorithm model. The knowledge acquired from training
model is stored in neural network locally and the weights
can be expressed as fuzzy rules. Therefore, it is suitable for
uncertain prediction of machine tool failure.
The life equation of ball screw can be express by:

(1)
( ]
Bi,1 = 1 x ∈ xi , xi+1 ; Bi,1 = 0 x ∈ others ( )3
Ca
L= × 106 (5)
x − xi xi+k − x fw Fa
Bi,k (x) = Bi,k−1 (x) + B (x),
xi+k−1 − xi xi+k − xi+1 i+1,k−1
In above equation, L is rated life, Ca is rated dynamic
k = 2, … , M, i = 1, … n (2)
load, Fa is axial load, fw is load factor. Fault prediction
For multiple variables, the basic function of B-splines model is trained by the fatigue fault data of same type parts.
can be expressed by: The initial data is obtained from the suppliers, and the run-
ning status data begins to update and accumulate after the
m m
∏ ∑ delivery of CNC milling machine tool.
Nk (x) = Bik ,n (xi ) k = 1, 2, … , M,
i i
M= Mi (3)
i=1 i=1

So the function y(x) of multiple variables can be numeri- 5.3 Using method

cal fitted by Nk (x):
As shown in Fig. 12, after DTMT is built, with the mapping
∑ M M
∑∏ m ability of DTMT, the sensed data can be collected and used
Bik ,n xi 𝜔k (4)
( )
y(x) ≈ Nk (x)𝜔k =
i i to drive the analysis and simulation with descriptive model
k=1 k=1 i=1
and algorithm model. Then fault can be predicted timely
Using B-splines fuzzy neural network, remaining useful before failure occurred by DTMT. Compared to traditional
life (RUL) of ball screw can be expressed by multiple vari- method, the driven data is collected by DTMT mapping
ables for different sensors. Vibration data and temperature strategy, which can ensure the timeliness, objectivity and
data are input to train the algorithm model. Collected data is accuracy, providing shop-floor level analysis and simula-
multidimensional, so input data is mapped to a matrix. The tion ability.

13

1140
6 Conclusion and future works
In this paper, a modelling method and using strategy of DT
for CNCMT is proposed. This paper gives a demonstra-
tion of DT concept in CNC machine tool era. The research
mainly includes the following aspects. First, it proposes a
DT modelling and application framework for CNCMT. Sec-
ond, a multi-domain modeling method using unified model-
ling language and mapping strategy is presented. Third, the
using strategy of DT: fault diagnosis and predict is stud-
ied. To validate our proposal, a case study based on above
method and strategy is researched. However, the research
still needs many works to fulfill the entire DT application.
Future work will focus on following aspects: (1) apply-
ing DTMT for hybrid approach predictive maintenance of
CNCMT; (2) realizing further modelling consistency and
accuracy according to experiment.
Acknowledgements  The work is supported by National Natural Sci-
ence Foundation of China (Grant no. 51405270).
References
Cho S, Asfour S, Onar A, Kaundinya N (2005) Tool breakage detection
using support vector machine learning in a milling process. Int J
Mach Tools Manuf 45(3):241–249. https:​ //doi.org/10.1016/j.ijmac​
htool​s.2004.08.016
Davis J, Edgar T, Porter J, Bernaden J, Sarli M (2012) Smart manu-
facturing, manufacturing intelligence and demand-dynamic
performance. Comput Chem Eng 47(12):145–156. https​://doi.
org/10.1016/j.compc​hemen​g.2012.06.037
Elmqvist H, Mattsson SE, Otter M (1998) Modelica—an international
effort to design an object-oriented modeling language, pp 333–339
Fei T, Meng Z, Cheng J, Qinglin QI (2017) Digital twin workshop: a
new paradigm for future workshop. Comput Integr Manuf Systems
23(1):1–9. https​://doi.org/10.13196​/j.cims.2017.01.001
Glaessgen E, D Stargel (2012) The Digital Twin paradigm for future
NASA and US Air Force Vehicles. In: AIAA/ASME/ASCE/AHS/
ASC Structures, Structural Dynamics and Materials Conference
Aiaa/asme/ahs Adaptive Structures Conference Aiaa. https​://doi.
org/10.2514/6.2012-1818
Grieves M, Vickers J (2017) Digital twin: mitigating unpredictable,
undesirable emergent behavior in complex systems. In: Kahlen
FJ, Flumerfelt S, Alves A (eds) Transdisciplinary perspectives on
complex systems. Springer, Cham. https​://doi.org/10.1007/978-
3-319-38756​-7_4
Ji S, Zhang C, Hu T, Wang K (2015) A hardware independent real-time
ethernet for motion control system. Int J Comput Commun Con-
trol 11(1):39. https​://doi.org/10.15837​/ijccc​.2016.1.617
Kraft EM (2015) The air force digital thread/digital twin—life
cycle integration and use of computational and experimental
knowledge. In: AIAA aerospace sciences meeting. https​://doi.
org/10.2514/6.2016-0897
Lee EA (2008) Cyber physical systems: design challenges. In: IEEE
international symposium on object oriented real-time distributed
computing, pp 363–369. https​://doi.org/10.1109/ISORC​.2008.25
Lee J, Bagheri B, Kao HA (2015) A cyber-physical systems architec-
ture for industry 4.0-based manufacturing systems. Manuf Lett
3:18–23. https​://doi.org/10.1016/j.mfgle​t.2014.12.001
13
W. Luo et al.
Liu YK, Xia H, Xie CL, Yan CQ (2004) Research on fault diagnostic
system of nuclear power plant based on fuzzy neural network.
Nucl Power Eng 63(1):3–9
Long H, Wang X (2009) Application of aircraft fuel fault diagnostic
expert system based on fuzzy neural network. In: Wase interna-
tional conference on information engineering, pp 202–205. https​
://doi.org/10.1109/ICIE.2009.9
M Association (2005) Modelica, a unified object oriented language for
physical systems modeling. Tutorial
Magargle R, Johnson L, Mandloi P, Davoudabadi P, Kesarkar O,
Krishnaswamy S, Batteh J, Pitchaikani A (2017) A simulation-
based digital twin for model-driven health monitoring and pre-
dictive maintenance of an automotive braking system. In: The
international modelica conference, Prague, Czech Republic, May,
pp 35–46. https​://doi.org/10.3384/ecp17​13235​
Moreno A, Velez G, Ardanza A, Barandiaran I, Ruíz de Infante A,
Chopitea R (2017) Virtualisation process of a sheet metal punch-
ing machine within the Industry 4.0 vision. Int J Interact Des
Manuf (IJIDeM) 11(2):365–373. https​://doi.org/10.1007/s1200​
8-016-0319-2
Pedrielli G, Scavardone P, Tolio T, Sacco M (2011) Simulation of
complex manufacturing systems via HLA-based infrastructure.
In: IEEE workshop on principles of advanced and distributed
simulation, pp 1–9. https​://doi.org/10.1109/PADS.2011.59367​72
Schroeder GN, Steinmetz C, Pereira CE, Espindola DB (2016) Digital
twin data modeling with automationML and a communication
methodology for data exchange. IFAC Pap OnLine 49(30):12–17.
https​://doi.org/10.1016/j.ifaco​l.2016.11.115
Tao F, Cheng J, Cheng Y, Gu S, Zheng T, Yang H (2017a) SDMSim: a
manufacturing service supply—demand matching simulator under
cloud environment. Robot Comput Integr Manuf 45(6):34–46.
https​://doi.org/10.1016/j.rcim.2016.07.001
Tao F, Cheng J, Qi Q, Tao F, Cheng J, Qi Q (2017b) IIHub: an indus-
trial internet-of-things hub towards smart manufacturing based
on cyber-physical system. IEEE Trans Ind Inform. https​://doi.
org/10.1109/TII.2017.27591​78
Tao F, Zhang M, Liu Y, Nee AYC (2018) Digital twin driven prognos-
tics and health management for complex equipment. Cirp Ann.
https​://doi.org/10.1016/j.cirp.2018.04.055
Tuegel EJ, Ingraffea AR, Eason TG, Spottswood SM (2011) Reengi-
neering aircraft structural life prediction using a digital twin. Int
J Aerosp Eng. https​://doi.org/10.1155/2011/15479​8
Wang GG (2002) Definition and review of virtual prototyping. J Com-
put Inf Sci Eng 2(3):232–236. https​://doi.org/10.1115/1.15265​08
Wang J, Xie J, Zhao R, Zhang L, Duan L (2016) Multisensory
fusion based virtual tool wear sensing for ubiquitous manufac-
turing. Robot Comput Integr Manuf 45(C):47–58. https​://doi.
org/10.1016/j.rcim.2016.05.010
Wang J, Wang K, Wang Y, Huang Z, Xue R (2018) Deep Boltzmann
machine based condition prediction for smart manufacturing.
J Ambient Intell Hum Comput. https​://doi.org/10.1007/s1265​
2-018-0794-3
Xu XW, Newman ST (2006) Making CNC machine tools more open,
interoperable and intelligent—a review of the technologies.
Comput Ind 57(2):141–152. https​://doi.org/10.1016/j.compi​
nd.2005.06.002
Zhang JS, Zhang YH (2012) Research of CNC fault diagnosis based
on RBF neural network. Appl Mech Mater 150:211–216. https​://
doi.org/10.4028/www.scien​tific​.net/AMM.150.211
Publisher’s Note Springer Nature remains neutral with regard to
jurisdictional claims in published maps and institutional affiliations.